Unitized sealed layer carton load



l ou.- 24, 1967 Filed May 5, 1966 G. C. BAHLS ETAL UNITIZED SEALED LAYER CARTON LOAD l 3 Sheets-Sheet 1 G 12 C /zsg 'z'ciff Zaza/eff@ EPI/Ce Oct 24, 1967 G. c. BAHLs ETAL UNITIZED SEALED LAYER CARTON LOAD y Filed May 5. 1966 5 Sheets-Sheet 2 oct- 24 1967. G. c. BAHLs ETAL 3,348,673

UNITIZED SEALED LAYER CARTON LOAD Filed May 5, 196e 5 sheets-shea sv fw mr 1 4 Gene cz,

WZ'CZOJ'?. Zic/eff Q42/ obefz Eprice I gy f United States Patent Oflice 3,348,673 Patented Oct. 24, 1967 The present invention relates to packaging, and is more particularly concerned with a method for packaging a plurality of folded and glued paperboard cartons, as Well as many other products which might otherwise be dam-aged by stacking weight, excessive handling, and particularly by humidity conditions and/ or contaminations, into a unit load of -completely sealed layers secured to a pallet bases and with the unit load provided thereby. As used herein, the terms board and paperboard are synonymous.

Folded and glued cartons and similar items have commonly been shipped by packaging them in small corrugated board containers. However, individual corrugated containers are diicult to handle in bulk, and are subject to damage and deterioration if such containers are piled to any great height. This is due largely to a tendency of the corrugated container, and/or corrugated support pads inside the container, to absorb moisture during periods of high relative humidity. Excess moisture weakens the corrugated container, causing partial collapse of loads and spoilage of cartons or other products contained therein. When unit loads of this type are double tiered, the bottommost containers may collapse due to weakening as a result of moisture absorption, giving rise to a safety hazard. Damage to glued cartons in corrugated containers is also caused by uneven stacking of such containers so that corner strength in the corrugated container is not properly utilized, in which case pressure points develop at points on the corrugated container not designed to Withstand this stacking weight. This also results in damage to contents of the container. Since the corrugated containers must be handled individually into and out of a freight car or truck, considerable damage to the cont-ainers and contents often occurs during such transfers. It is not unusual for the individual corrugated containers to be handled as many as ten times before they reach the customers lling mac-bine. Moreover, as the weight and size of these containers increase, there is a natural tendency for material handlers to drop or throw the container, further increasing the possibility of damage to its contents.

Recently the packaging industry has become interested in unitized loads in which a plurality of small paperboard cartons are placed into one large container. In order to render the unit load sufficiently strong to withstand the rigors of transportation,`it has been necessary to utilize heavy corrugated board as the outer container for the unitized load. This methodof packaging has found favor with the industry5 but is relatively expensive in practice because of the high cost of such large corrugated containers. However, previously proposed alternative solutions to the problem have suffered from one or more serious disadvantages such as lack of stability, rigidity, or resistance to moisture. Customers of the folding carton industry, as well as the industry itself, have also Ibecome interested in unitizing these small containers in order to reduce labor costs for materials handling and loading of freight cars and trucktrailers. Such attempts to reduce labor costs have resulted in greater material costs since an expendable type pallet must be procured for each unit load. Additional warehousing space is also required. Moreover, this alternate method has suffered from one or more serious disadvantages such as lack of stability, rigidity, resist-ance to moisture vapor and resistance to contamination by insects, dirt,

dust and other foreign materials, the latter aspect being of particular importance when the carton is to be used for packaging of a food or food related product.

In copending application Serial No. 365,054, led May 5, 1964J now Patent No. 3,289,828 a palletized unit load is disclosed and claimed which is provided by placing a pluraltiy of laye-rs on a pallet and securing the layers to the pallet by strap means. Each layer comprises a plurality of trays each containing a plurality of K.D. (knocked.

down) folded and glued paperboard cartons vertically arranged. A plurality of corrugated reinforcing pads are placed in each tray, at least one at each end of the tray, to increase the load Asupporting properties of the individual tray unit. A group of trays is placed in a layer on a pallet, and a unitary cover formed of paperboard and having depending flanges is placed over the entire group of trays of the layer. In a preferred embodiment, both the trays and the cover are formed of a cylinder board material which has been coated with a moisture-resistant plastic material such as polyethylene. Additional layers are added in a similar manner, and strap means utilized to bind the layers to the pallet. Although the resulting structure has been found to be generally satisfactory from the standpoint of strength, rigidity, impact-resistance, and cornpressive strength, it is still lacking in several import-ant properties. First, the pallet load is not completely protec-` tive against the entry of insects and other contaminants such as dirt and dust. Further, although the application of a polyethylene inner layer contributes a great deal to the exclusion-of -moisture when the pallet load is subiected to humid atmospheres an undesirably large amount of moisture still enters the load through the various openings present and may result in warping and general weakening of the structure.

In copending application Serial No. 451,740 a unitized load is disclosed and claimed having improved means for excluding vermin and other contaminants, comprising barrier flaps provided on the side walls of each tray. When the cover is placed over an entire layer of trays, the barrier flaps engage the cover with a resiliently biased force cooperating with the cover to form a barrier against the entrance of such contaminants. However, although improved protection is obtained thereby, it would be desirable to have completely positive sealing of each of the various layers of each pallet load, thereby insuring freedom from contaminants and permitting K.D. cartons to be packed therein in a manner which insures their suitability for subsequent use in packaging food products. It is an object of the present invention to provide an improved and novel method for pack-aging materials such as folded and glued paperboa-rd cartons in unitized loads. It is another object to provide such improved unitized loads which are highly resistant to moisture, impact, and vibration, and which will withstand the effects of heavy loads placed thereon, Iand which can moreover be carried or conveyed by normal means and in normal manner without danger of collapsing. It is another object to provide a pallet load wherein improved means are provided for excluding insects and Asubstantially reducing the amount of moisture which m-ay enter the load. It is a further object to provide a novel tray for use i-n forming a pallet load according to the invention having a readily openable end for dispensing K.D. cartons contained in the tray without'the necessity for lifting the cartons out of the open top of the tray. It is still a further object to provide a palletized load having means provided to prevent lateral displacement of the trays contained in the palletized unit load, and yet which permit the trays to be readily removed from the load by the operator of the set-up and filling equipment on which the contained cartons are utilized. It is a prime object to provide a package which is highly resistant to vermin, dirt, dust or other foreign material which might otherwise contaminate the product. It is another object to provide a novel container which may be easily opened at one end or from either end to permit rapid removal of the cartons directly into the customers filling machine. It is a further object to provide improved unitized loads of the type described which are afxed to a pallet base for easy handling. It is an additional object to provide an improved palletized unit load which is relatively inexpensive in practice. The accomplishment of the foregoing and additional objects will become more fully apparent hereinafter.

The invention in its preferred embodiment is illustrated by the accompanying drawings in which:

FIG. 1 is a perspective View of a palletized unit load according to the invention.

FIG. 2 is a plan view of a blank for forming an integra1 cap or cover.

FIG. 3 is a fragmentary perspective view of one corner of the cap in the process of being folded.

FIG. 4 is a perspective view of the completely erected cap formed from the blank of FIG. 2.

FIG. 5 is a plan view of an integral blank for forming a tray according to the invention.

FIG. 6 is a perspective view of a completely assembled tray having glued and folded cartons placed therein.

FIG. 7 is a side elevation of a completely filled and sealed layer for assembling into the unit load.

FIG. 8 is a vertical section of the layer shown in FIG. 7, and

FIG. 9 is a perspective view showing a tray containing folded cartons, and having its end opened for loading into an automatic filling machine.

According to the invention, a palletized unit load is provided by placing a plurality of layers on a pallet, each layer comprising a container such as an inverted cap or cover and containing a number of trays each having a plurality of K.D. (knocked-down) folded and glued paperboard cartons therein. A plurality of vertically arranged reinforcing members or pads, preferably U- shaped, are placed in each tray, and preferably at least one pair at each end of the tray, to increase the load supporting properties of the individual tray unit. A second cap or cover is placed over the contents contained in the first tray and a strip of tape is adhesively aixed over the juxtaposed edges of the two caps or covers and extending completely around the layer, thereby completely sealing the space defined by the two caps. The lower cap is adhesively axed to the pallet upon which it rests. Subsequent layers are added in similar manne-r and the lower inverted cap of each ofthe subsequent layers is adhesively aiixed to the upper cap of the layer immediately below. As a consequence, a pallet load is constructed which is coherent and which will withstand considerable moving and jostling about during transportation, even without the use of conventional reinforcing bands placed around the load. If desired however, such reinforcing bands of a material such as steel or plastic may be placed around the load in the usual manner where transportation or handling may be exceptionally rough. The resulting structure is strong, rigid,impactresistant, has high compressive strength, and offers excellent resistance against the entrance of insects, vermin, moisture and foreign materials.

Reference is now made to the' accompanying drawings for a better understanding of the invention, wherein all the parts are numbered and wherein the same numbers are used to refer to corresponding parts throughout.

' Referring to FIG. 1, a completely assembled palletized unit load is shown comprising a pallet 1, which is commonly constructed of wood, and a plurality of layers 2 arranged on the pallet. Each layer is provided with a container such as an inverted unitary base cap or cover 3 in which the contents are placed, and a unitary cap or cover' 4 placed over the'cap 3 and defining a chamber therewith. The covers may be so proportioned that their edges are in abutting engagement when the contents are inserted between the caps. Alternatively their edges may be somewhat spaced apart. An adhesive or sealing strip 5 is placed over the edges of bot-h the base cap and the upper cap completely around the layer, providing both mechanical securement and a positive seal for preventing moisture and contaminants from entering into the compartment de-fined by the inverted base cap 3, the top cap 4, and the sealing strip 5. The covers or caps 3 and 4 are preferably made of a cylinder type of paperboard. In the preferred form a moisture barrier such as a layer of polyethylene is provided on the inner surface of the caps. The lowest inverted cap 3 may be adhesively affixed to the pallet 1 and each successive inverted cap 3 adhered to the cap 4 immediately below. A plurality of layers are assembled on each pallet and may be secured thereto by means of straps 20 commonly made of steel or plastic such as Dymax strapping. Corrugated or berboard edge protectors 6 may be placed under the straps 20 at the edges of the top layers to prevent defacement or destruction thereof when a substantial force is applied by the straps 20.

Referring to FIG. 2, an integral blank of forming a cap 3 or 4 is shown provided with a major scores 7, 8, 9, and 10 defining a top or bottom panel 11, as the case may be, and side walls 12, 13, 14, and 15. In the preferred embodiment, the rect-angles 16 abutting the ends of the side walls are left intact. Moreover, diagonal scores 17 are provided in each corner. Consequently, when the cap is erected, the rectangular web folds inward, resulting in a continuous connection between the ends of abutting side walls, as shown in -detail in FIG. 3. This continuity between the ends of the side walls serves as a seal, preventing vermin and foreign matter from entering between the ends of the side walls. FIG. 4 illustrates a completely erected cap which is so maintained by means of strips of tape 18. The inner surface of the cap is provided with a liner of a material such as polyethylene to serve as a moisture barrier, the liner preferably being applied to the stock from which the blanks are cut.

Referring to FIG. 5, an integral blank is shown for forming a tray in its preferred form according to the invention, in .which -a plurality of KJD. cartons are to be loaded. As shown in the drawing, each tray 24 is comprised ofa bottom 25 and side panels or walls 26 and 27 hingedly connected thereto. Inner end wall iiaps 28, 29, 30, 31 are hingedly connected to the ends of the side panels 26 and 27, and outer end wall panels 32 and 33 are hingedly connected to the ends of the bottom 25. Foldover flaps 34 and 35 are hingedly connected to the upper edges of the outer end wall panels 32 and 33 and are folded over and engage the inner end wall flaps 28, 29, 30, and 31. One of the outer end wall panels 32 is provided with a horizontal severance line 36 provided as by perforating or scoring to facilitate opening the end of the carton. If desired, severance lines may be provided in both outer end wall panels. However, in particular applications it may be preferred to utilize a severance line only at one end, so that the K.D. cartons Within the tray may be inserted in a predetermined position, and the presence of the severance line serves as an index for ensuring that the proper end is opened in, order that the cartons will be properly presented to the automatic set-up machinery.

FIG. 6 illustrates a fully assembled tray partially filled with K.D. cartons 40. Whereas trays designed for the pallet load disclosed in the above-noted prior-filed applications are `necessarily designed so that the sides thereof are as high as or higher than the top edge. of the folded cartons in order to provide protection from crushing and to serve as a barrier to prevent vermin and contaminants from entering the tray, because the upper and lower caps in the present invention cooperate to seal the space contained between and defined by the caps, sealing of individual trays is no longer required. Consequently, as shown in FIG. 6, the walls of the tray may be substantially lower than the -height of the loaded cartons. It is desirable, however, that theV wall height be approximately at the midpoint and for some applications even higher than the midpoint in order to prevent cartons from falling out of the tray while being unloaded. In order to provide vertical compressive strength to prevent crushing of the carton, a plurality of corrugated reinforcing members or pads 41, as for example U-pads, preferably having vertical corrugations, are placed in the tray. Alternatively, the reinforcing pads may be prepared from heavy cylinder board, preferably two or more thicknesses glued together. The individual layers of the pads may be pre-scored prior to gluing the layers together in order to facilitate shaping the pads into U-form ora pair of U-pads in facing relationship, as shown in the drawings, is preferably placed at each end of the tray, thus defining three compartments. In order to provide the greatest compressive strength and protection for the contained K.D. cartons, theU- pads are so proportioned that the upper edges of the pads are approximately 1/s" above the height of the knocked-down cartons.

The pallet load of the present invention is constructed by first filling a group ofindividual trays with glued cartons, inserting U-shaped reinforcing pads, at least two pads in opposing position at each end of the tray, as illustrated in FIG. 6. An inverted cap 4 is then adhesively aixed to the wood pallet 1. If bands are to be placed over the entire load, merely a skid-proof type of adhesive is sufficient. However, if banding is to be dispensed with, a strong loadretaining adhesive should be used. The filled trays are placed in the inverted cap and a second cap 4 is placed thereover. The edges of the two caps are sealed to each other by means of a strip of adhesive tape 5 entirely encircling the joint between the two caps. Suitable tape materials are gummed kraft, various plastic tapes, and reinforced tapes such as those containing fiberglass filaments. A gummed paper tape such as PEALAC tape, disclosed in U.S. Patent No. 3,076,588, has been found particularly suitable,v providing a strong tight seal, and having the additional advantage that it may be subsequently readily removed by grasping one end and peeling the entire tapevfrom the cap assembly. A completely sealed layer is shown in FIGS. 7 and 8.

The remainder of the load is constructed by aixing subsequent inverted caps 4 to the completed layer immediately below, filling the caps with trays of cartons, placing a second cap thereover, and sealing the pair of caps together with tape in the same manner. It has been found that when a strong adhesive, such as a load-locking adhesive, is used between layers, the load may be utilized without banding for many purposes. However, where an exceptionally strong load is desired, particularly where the load is to be subjected to rough handling, banding with either steel or plastic banding material may be utilized in a conventional manner.

Further advantages of the unit load of the present invention become apparent when the load is disassembled. If banding has been utilized, the bands are first removed. The end of the tape sealing the caps of the uppermost layer is then grasped and the tape peeled from the side walls of the caps. The upper cap may then be lifted off and individual trays removed with their contents. Since the trays are not adhesively affixed to the surface upon which they rest, trays may be pushed and caused to slide along the bottom surface of the cap to a position which is more convenient for removal.

In an improved embodiment, a severance line 36 is provided in an end panel 32 of each tray which may be separated by suitable means. This permits the top of the outer end wall above the severance line together with the fold-over flap to be lifted out of the carton, allowing the remaining portion of the outer end wall to fold down and the inner end wall aps to be folded outward. This results in an open end through which the K.D. cartons may be removed or fed into an automatic set-up machine. Such structure is shown in FIGS. 5, 6 and 9. Alternatively,

the severance line may be positioned at or near the bottom of one or both outer end panels. As a result, when the severance line is broken, the entire end panel of the carton separates and lmay be removed. The entire tray of cartons may then be placed into a properly designed machine feed section to accomplish a magazine type feed of the tray contents. After the U-pads are removed, a backward pull on the cylinder board tray permits easy removal of the tray from the feed section, leaving a single row of cartons in the proper relative position for uninterrupted feeding of the machine. This method, made possible by the novel end structure of the tray, greatly reduces the workload of feeding the machine.

Although any type of pallet known in the art may be utilized in preparing the unit load of the invention, a preferred structure is shown in FIG. 1. In preparing the wood pallet in its preferred embodiment, the upper portion is formed by nailing six boards 30, the dimensions of which are 1/2 x 4" x 37, and one board 31, the dimensions of which are 1/2 x 6I x 37, to three stringers 32. The six-inch board is utilized to obtain a forty-inch dimension at this point so that, after unloading the trays from the pallet, the customer may make one cut across the 37-inch width of the pallet in order to obtain a standard 40-inch long pallet which is conventional for use with their own products. The bottom of the pallet is prepared by nailing four boards 33, the dimensions of which are 1/2 x 31/2 x 37, at the end of the pallet, and one board 34, the dimensions of which are 1/2" x 4 x 37, at the center of the pallet, to the stringers 32. A space of 1%" is provided between each pair of end boards to permit the placement of 1/z-inch wide strap therebetween. The dimensions of the stringers are ll/zI x 5" x.44%, each of which is provided with a 3 x 91/2" cutout to permit the entrance of either a manually or electrically operated pallet transporter, as well as conventional forklift trucks.

Viewed from the end of the pallet, the two end stringers are inset one inch each to obtain a thirty-six inch dimension. The most conventional fork length on a forklift truck is thirty-six inches. Insetting of the stringers in this manner ensures that the forks will be completely through all three stringers when the unit load is lifted from the side. Where this is not provided for, only two of the three stringers may rest on the truck, resulting in an unstable condition with regard to lifting and moving the unit load.

The palletized unit load of the present invention represents a significant improvement in the art. The invention enables palletized loads to be readily prepared which may be conveniently handled for shipment, and which successfully withstand vibration, impact and crushing, to which forces such loads are normally subjected in transit. Moreover, because the use of an expensive complete corrugated outer container is avoided, a substantial reduction in material cost is achieved. Further, by using cylinder board for the caps a polyethylene type coating can be readily applied to serve as improved protection against moisture which would otherwise weaken the package and cause damage t-o the product. As a prime advantage, each layer is completely sealed between each pair of caps, permitting less expensive trays to be used, While at the same time providing complete protection for the contents of each layer from vermin, contaminants, and moisture. This feature is extremely significant, particularly when the packaged K.D. cartons are to be used as food containers. The trays are constructed to permit unloading directly into a carton filling machine, resulting in substantial labor savings for the user.

An additional advantage of utilizing completely sealed layers formed by taping two caps together is that the individual trays need not be glued to the layer below. Consequently, the machine feeder can easily reach and slide each tray to his feeding position. Further, there is no need for exact alignment of each tray within the cap, thus reducing the assemblers work load. Also, because the number of reinforcing straps may be reduced or even eliminated for certain applications, the cost of strapping is considerably reduced.

It is to be understood that the invention is not limited to the exact details of construction, operation, or exact materials or embodiments shown and described, as obvious modifications and equivalents Will be apparent to one skilled in the art, and the invention is therefore to be limited only by the scope of the appended claims.

We claim:

1. In a palletized load comprising a pallet base and a plurality of layers secured thereto, the improvement wherein each of said layers comprises a unitary base container having a bottom panel and ascending side walls, a unitary cover having a top panel and depending side walls, and an adhesive strip adhesively afxed to both the side walls of said container and the side walls of said cover, said adhesive strip extending around and sealing the entire perimeter of said layer at the junction between said container and said cover thereby sealing the space delined by said container and said cover, said container having therein a plurality of paperboard trays each comprising a bottom panel, side wall panels and end wall panels connected thereto and having a plurality of articles arranged within said trays, and vertical reinforcing members arranged at least one at each end of each of said trays comprising a body member and end members disposed at right angles thereto, said layers thus being individually sealed against the intrusion of foreign matter thereby preventing the contents of said trays from becoming contaminated.

2. In a palletized load according to claim 1, the improvement wherein the lowest layer is adhesively affixed to said pallet and each successive layer is adhesively affixed to the layer below.

3. In a palletized load according to claim 1, the improvement wherein said container and said cover each have a lm of a moisture-proof material applied to a surface thereof.

4. In a palletized load according to claim 1, the improvement wherein said containers and said covers have a continuous web connecting the ends of the side walls thereof.

5. In a palletized load according to claim 1, the improvement wherein each tray contains at least two pairs of U-shaped reinforcing members, each pair being arranged in facing relationship and positioned at -an end of the said tray, whereby at least three compartments are defined.

6. In a palletized load according to claim 5, the improvement wherein the upper edges of said reinforcing members are at a higher level than the upper edges of the contents contained within said tray.

7. In a palletized load according to claim 1, the improvement wherein each of said trays comprises a bottom panel, a pair of side panels hingedly connected thereto, each side panel having a pair of end flaps, and a pair of end wall panels each hingedly connected at one end to sai-d bottom panel and having a fold-over flap at the other end folded over and engaging a pair of end flaps of said side panels, at least one of said end wall panels being provided with a severance line connecting the two vertical edges thereof, whereby an end of said tray may be removed by tearing said end wall panel at said severance line and removing said fold-over ap and the portion of said end wall panel attached thereto.

S. In a palletized load according to claim 7, the improvement wherein said severance line is substantially horizontally positioned in the upper portion of said end wall panel.

9. In a palletized load according to claim 7, the improvement wherein said severance line is horizontally positioned substantially at the bottom of said end wall panel.

10. In a palletized load according to claim 1, the improvement wherein banding is provided securing said layers to said pallet.

References Cited UNITED STATES PATENTS 3,069,007 12/1962 Crane 20G-65 THERON E. CONDON, Primary Examiner.

M. L. RICE, Assistant Examiner. 

1. IN A PALLETIZED LOAD COMPRISING A PALLET BASE AND A PLURALITY OF LAYERS SECURED THERETO, THE IMPROVEMENT WHEREIN EACH OF SAID LAYERS COMPRISES A UNITARY BASE CONTAINER HAVING A BOTTOM PANEL AND ASCENDING SIDE WALLS, A UNITARY COVER HAVING A TOP PANEL AND DEPENDING SIDE WALLS, AND AN ADHESIVE STRIP ADHESIVELY AFFIXED TO BOTH THE SIDE WALLS OF SAID CONTAINER AND THE SIDE WALLS OF THE COVER, SAID ADHESIVE STRIP EXTENDING AROUND AND SEALING THE ENTIRE PERIMETER OF SAID LAYER AT THE JUNCTION BETWEEN SAID CONTAINER AND SAID COVER THEREBY SEALING THE SPACE DEFINED BY SAID CONTAINER AND SAID COVER, SAID CONTAINER HAVING THEREIN A PLURALITY OF PAPERBOARD TRAYS EACH COMPRISING A BOTTOM PANEL, SIDE WALL PANELS AND END WALL PANELS CONNECTED THERETO AND HAVING A PLURALITY OF ARTICLES ARRANGED WITHIN SAID TRAYS, AND VERTICAL REINFORCING MEMBERS ARRANGED AT LEAST ONE OF EACH END OF EACH OF SAID TRAYS COMPRISING A BODY MEMBER AND END MEMBERS DISPOSED AT RIGHT ANGLES THERETO, SAID LAYERS THUS BEING INDIVIDUALLY SEALED AGAINST THE INTRUSION FOREIGN MATTER THEREBY PREVENTING THE CONTENTS OF SAID TRAYS FROM BECOMING CONTAMINATED. 